Top opening ice cream carton



July 27, 1965 R. M. HOLMES TOP OPENING ICE CREAM CARTON 5 Sheets-Sheet 1Filed Sept. 27, 1962 ATTORNE y S July 27, 1965 R. M. HOLMES TOP OPENINGICE CREAM CARTON 3 Sheets-Sheet 2 Filed Sept. 27, 1962 FIG. 5

INVENTOR. RAYNOR M. HOLMES JAM/- A oRwE 's July 27, 1965 R. M. HOLMESTOP OPENING ICE CREAM CARTON 3 Sheets-Sheet 3 Filed Sept. 27, 1962INVENTOR RAYNOR M. HOLMES United States Patent Delaware Filed Sept. 27,1962, Ser. No. 226,627 Claims. (Cl. 229-51) The present inventionrelates to paperboard cartons or containers for various products,including, specifically, ice cream. In particular, the invention isdirected to specific and substantial improvements in car-tons for icecream and the like, the cartons being of the type which are sealed atthe ends after filling, thereafter being opened and reclosed from thetop. The present invention is related to the invention of my prior,copending application Ser. No. 215,602, filed August 8, 1962, for SealedEnd Ice Cream Carton, and the present application constitutes acontinuation in part of said prior application.

In the packaging of ice cream in particular, it is conventional to fillthe containers from one end, and it has been common in the past to makeice cream cartons of end-opening construction, so that the contents ofthe package were accessible to the consumer through the carton end.Although it has been considered desirable to so construct ice creamcartons that, after sealing, the carton ends were permanently sealed,with access to the contents being had through the top of the carton,substantial unexpected complications in the actual carton design havearisen, which have prevented widespread use of such cartons in the past.In my above-mentioned, copending application, certain novel cartonconstruction features are described and claimed, which provide a sealedend, top opening carton of substantial commercial desirability, and, inaccordance with the present invention, certain specifically novelmodifications are provided, which further extend the desirability andusefulness of the carton.

In accordance with commercial practices, consumer acceptances, etc., aparticularly popular type of ice cream carton is the half-gallon size,rectangular carton measuring approximately 3 /8 inches by 5 inches onthe ends and having a length of about 6%; inches, and the invention ofthe present application, as well as the invention of my copendingapplication, is directed specifically to cartons of this general type.It will be understood, however, that the operative principles of theinvention have broader application, particularly as regards the actualcarton dimensions and capacity.

Whereas the carton specifically illustrated and described in myabove-mentioned copending application is so arranged that the broad sideof the rectangular carton forms the reclosable top, the carton structureof the present invention and application is so arranged that the narrowside of the carton forms the reclosable top. At the same time, theconstruction of the carton enables it to be handled and filled withconventional filling machinery.

More specifically, the carton of the present invention incorporates anovel sealed end construction including front and back end flaps and topand bottom end-closing flaps, the latter being arranged to be foldedinto substantially abutting, non-overlapping relation to present asmooth, uniform outer surface. The top end-closing flap, forming the endwall of the reclosable cover, is det-ach ably connected to the back endflap in a novel manner, enabling the cover readily to be freed from thebody of the container for opening.

In one specifically advantageous form of the invention, the detachableconnection between the top end-closing flap and the back end flapcomprises a separable upper section of the back end flap, which issecured to the inner 3,197,114 Patented July 27, 1965 surface ofandhidden by the top en-closing flap. The arrangement is particularlyadvantageous with respect to its uniform and pleasing outwardappearance, even after opening of the carton. In a second advantageousform of the invention, the detachable connection is provided by aseparable rear corner section of the top end-closing flap, which issecured to the back end flap and remains attached thereto when the coveris opened.

For a better understanding of the above and other specific advantageousfeatures of the invention, reference should be made to the followingdetailed description and to the accompanying drawing in which;

FIG. 1 is a plan view of a blank used in forming a first advantageousform of carton incorporating the features of the invention;

FIG. 2 is a fragmentary perspective view of a carton made of the blankof FIG. -'1 illustrating the carton prior to closing and sealing of itsend structure;

FIG. 3 is a fragmentary perspective view of the carton of FIG. 2, afterclosing and sealing of the end and with the cover in an open position;

FIG. 4 is an end elevation-a1 view showing the carton of FIG. 2 insealed and closed condition;

FIG. 5 is a fragmentary plan view of a blank, similar generally to theblank of FIG. 1, but differing in the areas encompassed by theillustration, for making a second advantageous form of the new carton;

FIG. 6 is a fragmentary, perspective view. of a carton made from theblank of FIG. 5, the carton being illustrated prior to closing andsealing of the end structure; and

FIG. 7 is a fragmentary, perspective view of the carton of FIG. 5 afterclosing and sealing of the ends and with the cover open.

Referring now to the drawing, and initially to FIG. 1 thereof, thereference numeral It) designates generally a blank formed of paperboardand scored transversely along lines 11-14 to form, in rightto-leftsequence a front wall panel 15, a bottom wall panel 16, a back wallpanel 17, a cover panel 18 and a front-closing panel 19. The oppositeend edges of the respective panels are formed by parallel, longitudinalscore lines 20, 21, such that the various panels are of generallyrectangular configuration. In an advantageous form of carton, suitablefor holding one-half gallon of ice cream, the front and back wall panelswill have a height dimension of approximately 4% inches and a lengthdimension of 6% inches, while the top and bottom walls advantageouslyhave a width of about 3 /2 inches and a length of about 6% inches. Thefront wall panel 19, which advantageously is divided into an uppersection 19a and a lower section 1%, by means of a transverse tear strip19c can have a variety of height dimensions, but it is advantageous thatthe height dimension of the upper portion 19a be about 1% inches and notsubstantially in excess thereof.

As illustrated in FIG. 1, a pair of flaps 22, hereinafter referred to asfront end flaps, are foldably connected to the end edges of the frontwall panel 15, the flaps 22 advantageously being of rectangularconfiguration and having a length approximately equal to the width ofthe bottom and cover panels 16, 18. A second pair of flaps 23,hereinafter referred to as bottom end-closing flaps, are foldablyconnected to the opposite end edges of the bottom wall panel 16, theflaps having a predetermined free length advantageously equal to thefree length of the front end flaps 22. A third pair of flaps 24,hereinafter referred to as the back end flaps, are foldably connected tothe opposite end edges of the back wall panel 17 and have relativelyshort free length advantageously of about 1% inches. A fourth pair offlaps 25, hereinafter referred to as top end-closing flaps, are foldablyconnected to the opposite end edges of the cover panel 18. The flaps 25have a free length which closely approximates but does not exceed thedifference between the carton height and the length of the bottomend-closing flaps '23; typically this will be 1 to'1 /s inches, in ahalf-gallon size carton. A fifth pair of flaps 26, hereinafter referredto as securing flaps, are foldably connected to the opposite end edgesof the upper section 19a of the front closing panel.

In accordance with one aspect of the invention, the back Wall panel 17is divided by a transverse score line 27 into a lower portion 17a and anupper portion 17b. Likewise, the back end flaps 24 are diveded by cutscores 28 into lower sections 24a and separable upper sections 24b. Asillustrated in FIG. 1, the cut scores 28 are disposed at an angle to thetransverse score line 27 such that, in the erected carton to bedescribed, the cut scores extend from the free forward edges of the backend flaps 24 in an upward and rearward direction into intersectingrelation to the score line 27.

In conjunction with the making of the blank 10, it is advantageous toapply a thermoplastic, heat scalable composition to preselected areas ofcertain flaps, to provide for proper closing and sealing of the cartonin subsequent operations to be performed at a packagers place ofbusiness. Specifically, the bottom end-closing flaps 23 advantageouslyare provided with spaced strips 29, 30 of thermoplastic composition,extending along the opposite, vertical, edges of the flap substantiallyfrom the bottom edges to. the top edges thereof. In addition, heat sealcomposition is applied to the separate areas 31, 32 of the topend-closing flaps 25, generally rectangular areas 31 being applied inthe forward portions of the flaps 25 and specially shaped areas 32 beingprovided in the back areas of the flaps 25 such that, in the erected andclosed carton, the areas 32 overlie only the separable upper sections25b of the back end flaps 24.

In the manufacturers plant, glue or other suitable adhesive is appliedto the lower section 1% of the front closing panel, and the blank isthereafter folded, first along the score line 11 and then along thescore line 13, until the adhesively coated panel section 19b is broughtinto contact with and secured to the front wall panel 15. The blank isthen in the form of a fiattended tube, which is convenient and compactfor shipping to the packager who, in this instance, typically will be anice cream packager and/ or manufacurer.

At the packagers plant the tube is squared, one end is closed, and thecontents (e.g., ice cream) are introduced through the other, still openend, which is thereafter closed, and the entire carton is sealed.

In accordance with the invention, a carton end is closed by firstfolding the front end flap 22 at right angles to the front wall panel15, the size and shape of the front end flap 22 being such astosubstantially completely close off the theretofore open end of theerected tube. Thereafter, the back end flap 24 is foldedforward at rightangles to the back wall panel 17, into overlying relation to a marginalportion of the front end flap 22. Advantageously, the securing flap 26is folded along with the front end flap 22, and overlies the upper frontcorner portion of the end flap, but is not secured thereto.

With .the flaps 22, 24 and 26 folded as above described, but unattachedto each other or to other parts of the carton, the top and bottomend-closing flaps 23, 25 are folded over the carton end, intosubstantially abutting but non-overlapping relation, and heat is appliedto the carton end in such a way as to bond the end-closing flaps 23, 25to the underlying flaps in the specific areas engaged by thepredetermined areas of heat seal composition 29, 32. Thus, the bottomend closing flap 23' is'bonded to the lower portion 24a of the 'back'endflap, along the vertical heat seal strip 29, and to the'front end flap22, along the vertical heat seal strip .30. Likewise, the topend-closing flap 25 is bonded to securing flap 26 between heat seal area31 and to the separable upper section 24b of the back end flap betweenheat seal be opened by removing the tear strip 190, to detach the panelsection 19a, forming the depending front wall of the cover, from theadhesively secured lower panel section 19b. The cover may then be swungupward about the hingeaxis formed by the score line 27, substantially asindicated in FIG. 3. Since the upper sections 241) of the back'end flapsare secured to the end walls of the cover, formed by the top end-closingflaps 25, the sections 24b are separated along the cut scores 28 duringopening of the cover, the cut scores being so designed as to accommodatesuch separation reliably and without ditliculty.

The once-opened carton may be reclosed and reopened as often asnecessary. Advantageously, a predetermined amount of interference isprovided between the cover and the carton body, slightly impedingopening and closing movements, so that the cover tends to beself-locking when reclosed. I

As indicated particularly in FIG. 4, the end surface of thecarton,formed by the end-closing flaps 23, 25,is substantially smooth anduniform, providing a desirable surface for presenting advertising,decorative designs, etc. This is achieved by arranging the end-closingflaps to fold into substantially abutting, but non-overlapping relation.

As a practical matter, the length of the bottom endclosing flaps 23 islimited substantially to the width of the carton, since to extend thelength farther would involve significant waste of paperboard. This willbe understood by reference to FIG. 1, in which the flaps 23 extendupward, even with the edges of the front end flaps 22, the length of.the latter being substantially equal to the width of the carton. Thelength of the bottom end-closing flaps being thus limited, it isnecessary to extend the top end-closing flaps downward a distancesufiicient to establish the desired substantial abutting,non-overlapping relation. In a half-gallon carton of standarddimensions, this involves extending the top end-closing flaps 25 about 1to 1% inches. And, since it is desirable to limit the downward extensionof the front-closing panel section 19a (forming the front wall of thecover) to 1% inches, the cover end wall desirably projects slightlybelow the cover front wall, as shown best in FIGS. 3 and 4..

In the above-described form of the new carton, a desired, detachableconnection is established between the flaps 24 and 25 by providing aseparable upper section 241: of the back end flap and arranging for theend-closing flap 25 to be bonded to the flap 24 only in the area of theseparable upper section 24b thereof. In addition, the separable uppersection 24b is concealed behind the end-closing flap 25 in anadvantageous manner by locating the forward and lower extremity of thecut score 28 above the lower edge of the end-closing flap 25.

Referring now to FIGS. 5-7, there is shown a second advantageous form ofthe new reclosable carton incorporating a generally similar butspecifically different end construction. Since many of the panels andflaps of the carton of FIGS. 5-7 are substantially identical to those ofthe carton of FIGS. 1-4, duplicate descriptions will "be omitted, andcorresponding reference numerals will be utilized where appropriate, toindicate corresponding elements.

Referring first to FIG. 5, the paperboard blank used in making thealternate form of carton differs from the blank of FIG. 1 in that theback end flaps 124 are integral throughout, rather than being dividedinto separable upper and lower portions. The top end-closing flap 125 ofthe FIG. 5 blank, on the other hand, is divided by a diagonal cut score4t) into separable front and rear flap sections 125a, 125b respectively,the front flap section 125a being provided near its front edge with arectangular area 131 of heat seal composition and the rear flap sections1255b being provided with a triangular heat seal area 132.

The carton of FIGS. 5-6 is erected and closed in the same manner as thecarton of FIGS. l-4, except that the sealing of the upper rear portionsof the carton ends is limited to the triangular area 132, of thealternate carton form, rather than the somewhat trapezoidal area 32 ofthe first described carton form. The arrangement is such that the bottomend-closing flap 23 is bonded to the back and front end flaps 124, 22respectively, the front portion 125a of the top end-closing flap isbonded to the securing flap 26, and the separable back section 12512 ofthe top end-closing flap is bonded to the upper portion of the back endflap 124. The closed and sealed end of the carton of FIGS. 5-7 issubstantially identical to that of the carton of FIGS. 1-4 except forthe presence of the cut score 40, which extends from the lower edgeextremity of the top end-closing flap 125 upward and rearward, generallytoward but somewhat below a hinge axis 127, which is advantageouslyformed at the upper edge extremity of the back wall 17, rather thanbelow the upper edge as in the carton of FIGS. l-4.

The carton of FIGS. 5-7 is opened by removing the tear strip 19c andraising the cover about the hinge axis 127. In opening the cover, thetop end-closing flap 125 separates along the cut score 40, with thesmall flap section 125b remaining attached to the back end flap 124.

In either of the illustrated forms of the invention, a novel andimproved reclosable ice cream carton is provided in which the reclosablecover closes a narrow side of the carton, so that access is had to thecontents with the carton in an upright position. Both illustrated formsof the new carton include a novel sealed end construction, in whichcooperating top and bottom end-closing flaps are brought intosubstantially abutting, non-overlapping relation, to provide a smooth,continuous outer surface particularly suitable for presentingadvertising, brand identification, etc., all while keeping the endstructure of the carton such as to enable filling of the carton to becarried out by conventional automatic filling machinery.

It should be understood, however, that the specific forms of theinvention herein illustrated and described are intended to berepresentative only, as certain changes may be made therein withoutdeparting from the clear teachings of the disclosure. Accordingly,reference should be made to the following appended claims in determiningthe full scope of the invention.

1. A top opening telescopically reclosable, end fillable carton for icecream and other products, which comprises (a) foldably connected frontwall, bottom wall, back wall and top wall panels arranged to form atube,

(b) a pair of front end wall flaps foldably connected to the oppositeend edges of the front wall panel and of a size and shape substantiallyto close the ends of said tube,

(0) a pair of back end Wall flaps of less than full carton Widthfoldably connected to the opposite end edges of the back wall panel andfolded to overlie marginal portions only of said front end wall flaps,

(d) a front-closing panel foldably connected to the front edge of saidtop wall panel and extending downward in overlying relation to saidfront wall panel,

(e) said front-closing panel having separable upper and lower portionsand being secured to said front wall panel by its lower portion,

(f) a pair of securing flaps foldably connected to the opposite endedges of the upper portion of said frontclosing panel and overlyingouter surface portions of said front end flaps,

(g) a pair of top end-closing flaps foldably connected to and extendingdownward from the opposite end edges of the top wall panel,

(h) said top end-closing flapsoverlying the outer sur- 6 faces of andbeing attached to said securing flaps and to upper end margins of saidback end flaps, and

(i) a pair of bottom end-closing flaps foldably connected to theopposite end edges of the bottom panel and extending upward therefrominto abutting, nonoverlapping relation with the upper end-closing flaps,

(3') said bottom end-closing flaps overlying and being secured to lowerportions of said front and back end flaps,

(1;) said top wall panel, the upper portion of said frontclosing panel,said securing flaps, and said top endclosing flaps defining atelescopically reclosable cover connected on a predetermined hinge axisin the back wall panel of the carton,

(I) said top end-closing panels and said upper marginal portions of saidback end flaps being secured by rupturable fastening means disposedinteriorly of the normally exposed exterior carton surfaces and beingconcealed before opening and after reclosing of said carton,

(111) said fastening means being rupturable upon opening movement ofsaid top panel, whereby severance of said upper and lower portions ofsaid front-closing panel and rupture of said fastening means forms atelescopically, reclosable cover.

2. The carton of claim 1, in which (a) said rupturable fastening meanscomprises a separable section formed at each end of the carton in saidback end flap and secured to said top end-closing flap,

(b) said separable section at each end being formed by a cut score insaid flap extending for substantially the full Width of said flap froman edge of said flap in a rearward and upward direction,

(0) said separable sections constituting the only substantial connectionbetween said top end-closing flaps and said back end flaps.

3. The carton of claim 2, in which (a) said hinge axis is located belowthe upper edge of said back wall panel and above the lower edges of saidtop end-closing flaps,

(b) saidcut scores extend from the front edges of said back end flaps ina rearward and upward direction substantially into intersecting relationwith said hinge axls,

(c) said separable sections being secured to the inner surfaces of saidtop end-closing flaps and being retained therewith upon hinged openingof said cover.

4. The carton of claim 3, in which (a) the forward ends of said cutscores lie above the lower edges of said top end-closing flaps.

5. The carton of claim 1, in which,

(a) the vertical dimensions of said bottom end-closing flaps aresubstantially equal to the horizontal dimensions of said front endflaps, and

(b) the vertical dimensions of said top end-closing flaps are slightlyin excess of the vertical dimensions of the upper portions of said frontclosing panel.

References Cited by the Examiner UNITED STATES PATENTS 2,038,893 4/36Davidson 22951 2,314,849 3/43 Sullivan et a1. 206-58 2,354,543 7/44Ratclifr' 22951 2,835,594 5/58 Felt et al. 229-51 3,000,548 9/61 Frazier229-51 3,003,674 10/61 Ringler 22951 3,018,942 1/ 62 Arneson 229-513,078,030 2/63 Gorton 229-44 3,085,736 4/63 Meyers 22951 FRANKLIN T.GARRETT, Primary Examiner.

T HERON E. CONDON, Examiner.

1. A TOP OPENING TELESCOPICALLY RECLOSEABLE, END FILLABLE CARTON FOR ICECREAM AND OTHER PRODUCTS, WHICH COMPRISES (A) FOLDABLY CONNECTED FRONTWALL, BOTTOM ALL, BACK WALL AND TOP WALL PANELS ARRANGED TO FORM A TUBE,(B) A PAIR OF FRONT END WALL FLAPS FOLDABLY CONNECTED TO THE OPPOSITEEND EDGES OF THE FRONT WALL PANEL AND OF A SIZE AND SHAPE SUBSTANTIALLYTO CLOSE THE ENDS OF SAID TUBE (C) A PAIR OF BACK END WALL FLAPS OF LESSTHAN FULL CARTON WIDTH FOLDABLY CONNECTED TO THE OPPOSITE END EDGES OFTHE BACK WALL PANEL AND FOLDED TO OVERLIE MARGINAL PORTIONS ONLY OF SAIDFRONT END WALL FLAPS, (D) A FRONT-CLOSING PANEL FOLDABLY CONNECTED TOTHE FRONT EDGE OF SAID TOP WALL PANEL AND EXTENDING DOWNWARD INOVERLYING RELATION TO SAID FRONT WALL PANEL, (E) SAID FRONT-CLOSINGPANEL HAVING SEPARABLE UPPER AND LOWER PORTIONS AND BEING SECURED TOSAID FRONT WALL PANEL BY ITS LOWER PORTION, (F) A PAIR OF SECURING FLAPSFOLDABLY CONNECTED TO THE OPPOSITE END EDGES OF THE UPPER PORTION OFSAID FRONTCLOSING PANEL AND OVERLYING OUTER SURFACE PORTIONS OF SAIDFRONT END FLAPS, (G) A PAIR OF TOP END-CLOSING FLAPS FOLDABLY CONNECTEDTO AND EXTENDING DOWNWARD FROM THE OPPOSITE END EDGES OF THE TOP WALLPANEL, (H) SAID TOP END-CLOSING FLAPS OVERLYING THE OUTER SURFACES OFAND BEING ATATACHED TO SAID SECURING FLAPS AND TO UPPER END MARGINS OFSAID BACK END FLAPS, AND (I) A PAIR OF BOTTOM END-CLOSING FLAPS FOLDABLYCONNECTED TO THE OPPOSITE END EDGES OF THE BOTTOM PANEL AND EXTENDINGUPWARD THEREFROM INTO ABUTTING, NONOVERLAPPING RELATION WITH THE UPPEREND-CLOSING FLAPS, (J) SAID BOTTOM END-CLOSING FLAPS OVERLYING AND BEINGSECURED TO LOWER PORTIONS OF SAID FRONT AND BACK END FLAPS, (K) SAID TOPWALL PANEL, THE UPPER PORTION OF SAID FRONTCLOSING PANEL, SAID SECURINGFLAPS, AND SAID TOP ENDCLOSING FLAPS DEFINING A TELESCOPICALLYRECLOSABLE COVER CONNECTED ON A PREDETERMINED HINGE AXIS IN THE BACKWALL PANEL OF THE CARTON, (L) SAID TOP END-CLOSING PANELS AND SAID UPPERMARGINAL PORTIONS OF SAID BAKC END FLAPS BEING SECURED BY RUPTURABLEFASTENING MEANS DISPOSED INTERIORLY OF THE NORMALLY EXPOSED EXTERIORCARTON SURFACES AND BEING CONCEALED BEFORE OPENING AND AFTER RECLOSINGOF SAID CARTON, (M) SAID FASTENING MEANS BEING RUPTURABLE UPON OPENINGMOVEMENT OF SAID TOP PANEL, WHEREBY SEVERANCE OF SAID UPPER AND LOWERPORTIONS OF SAID FRONT-CLOSING PANEL AND RUPTURE OF SAID FASTENEINGMEANS FORMS A TELESCOPICALLYY, RECLOSABLE COVER.